Apparatus and method for rigidly joining construction elements to one another

Abstract

An apparatus and method for rigidly joining construction elements to one another based on providing construction elements each having a connecting bore formed therethrough, positioning elements each having a connecting bore formed therethrough for aligning the connecting bores of adjacent construction elements, and partially expandable locking means dimensioned to extend through the aligned connecting bores of at least two construction elements and one positioning element. The construction elements and positioning elements are further equipped with engagement grooves and engagement ribs, respectively, for positioning adjacent construction elements in any number of predetermined angles. The locking mechanism has a radially expanding portion capable of locking the previously positioned construction elements in a rigid fashion.

What is claimed is: 
     
       1. A system for rigidly joining a first construction element to a second construction element, comprising: a first construction element and a second construction element each having a connecting bore formed therethrough, a first pair of engagement grooves extending laterally away from a first end of said connecting bore, and a second pair of engagement grooves extending laterally away from a second end of said connecting bore;   positioning means for positioning said first construction element relative to said second construction element, said positioning means having a connecting bore formed therethrough, a first pair of engagement ribs extending laterally away from a first end of said connecting bore, and a second pair of engagement ribs extending laterally away from a second end of said connecting bore, said positioning means being disposed between said first and second construction elements such that said connecting bore of said positioning means is substantially coaxial with said connecting bores of said first and second construction elements, said positioning means being disposed between said first and second construction elements such that said first pair of engagement ribs are engagedly coupled within said second pair of engagement grooves of said first construction element and said second pair of engagement ribs of said positioning means are engagedly coupled within said first pair of engagement grooves of said second construction element; and   partially expandable locking means for rigidly locking said first construction element relative to said second construction element, said partially expandable locking means being disposed at least partially within said connecting bore of said first construction element, at least partially within said connecting bore of said second construction element, at least partially within said connecting bore of said positioning means, and partially expanded to thereby affix said first construction element in rigid relation to said second construction element.   
     
     
       2. The system as set forth in claim 1 and further, said locking means comprising a generally elongate expansion member having a first end and a second end, said second end being capable of radial expansion. 
     
     
       3. The system as set forth in claim 2 and further, said locking means comprising a generally cylindrical dowel member for causing said second end of said elongate expansion member to radially expand. 
     
     
       4. The system as set forth in claim 3 and further, said elongate expansion member comprising a generally cylindrical tubular member having a first end, a second end, a non-expanding portion extending between said first end and a junction point, and an expanding portion extending between said junction point and said second end, said non-expanding portion having a fixed external radius, said expanding portion comprising a plurality of flexible expansion leaves which curve radially inward from said junction point to said second end, wherein the introduction of said dowel member into said expanding portion forces said plurality of flexible expansion leaves into contact with said second construction element. 
     
     
       5. The system as set forth in claim 4 and further, said generally tubular member including an upper lip member extending radially outward from said upper portion of said tubular member for engagement with said first end of said connecting bore of said first construction element. 
     
     
       6. The system as set forth in claim 5 and further, said expanding portion of said generally cylindrical tubular member including a lip member extending angularly and radially away from each of said plurality of flexible expansion leaves for biasing said first and second construction elements together as said dowel member is introduced into said expanding portion. 
     
     
       7. The system as set forth in claim 1 and further, said connecting bores of said first and second construction elements comprising a first end portion, a second end portion, and a middle portion, said first end portion extending between said middle portion and said first end of said connecting bore, said second end portion extending between said middle portion and said second end of said connecting bore, said first and second end portions having generally the same radius, said middle portion having a smaller diameter than the diameter of said first and second end portions. 
     
     
       8. The system as set forth in claim 7 and further, said locking means comprising a generally elongate expansion member having a first end and a second end, said first end having a lip member for engagement with said first end portion of said connecting bore of said first construction element, said second end having a lip member for engagement with said second end portion of said connecting bore of said second construction element, and said second end of said elongate expansion member being capable of radially expanding so as to bias said first construction element towards said second construction element. 
     
     
       9. The system as set forth in claim 7 and further, said second surface of said positioning means including a rim portion extending generally perpendicularly from the plane of said connecting bore of said positioning means, said rim portion being dimensioned to engage with said first end portion of said connecting bore of said second construction element. 
     
     
       10. A system for rigidly joining a first construction element to a second construction element in a variety of predetermined angles, comprising: a first construction element and a second construction element each having a connecting bore formed therethrough, a first pair of engagement grooves extending laterally away from a first end of said connecting bore, and a second pair of engagement grooves extending laterally away from a second end of said connecting bore;   first and second positioning means for positioning said first construction element relative to said second construction element, each of said first and second positioning means having a first generally planar surface, a second generally planar surface, and a connecting bore extending between said first and second generally planar surfaces, said first generally planar surface having a plurality of engagement ribs extending laterally away from said connecting bore, said second generally planar surface having a pair of engagement ribs for matingly engaging with said engagement grooves disposed within said first and second construction elements, said first and second positioning means being disposed between said first and second construction elements such that said connecting bores of said first and second positioning means are substantially coaxial with said connecting bores of said first and second construction elements and such that said plurality of engagement ribs of said first positioning means matingly engage with said plurality of engagement ribs of said second positioning means to selectively orient said first construction element in any of a variety of predetermined angles with respect to said second construction element; and   partially expandable locking means for rigidly locking said first construction element relative to said second construction element, said partially expandable locking means being disposed at least partially within said connecting bore of said first construction element, at least partially within said connecting bore of said second construction element, at least partially within said connecting bore of said positioning means, and partially expanded to thereby affix said first construction element in rigid relation to said second construction element.   
     
     
       11. The system as set forth in claim 10 and further, said locking means comprising a generally elongate expansion member having a first end and a second end, said second end being capable of radial expansion. 
     
     
       12. The system as set forth in claim 11 and further, said locking means comprising a generally cylindrical dowel member for causing said second end of said elongate expansion member to radially expand. 
     
     
       13. The system as set forth in claim 12 and further, said elongate expansion member comprising a generally cylindrical tubular member having a first end, a second end, a non-expanding portion extending between said first end and a junction point, and an expanding portion extending between said junction point and said second end, said non-expanding portion having a fixed external radius, said expanding portion comprising a plurality of flexible expansion leaves which curve radially inward from said junction point to said second end, wherein the introduction of said dowel member into said expanding portion forces said plurality of flexible expansion leaves into contact with said second construction element. 
     
     
       14. The system as set forth in claim 13 and further, said generally tubular member including an upper lip member extending radially outward from said upper portion of said tubular member for engagement with said first end of said connecting bore of said first construction element. 
     
     
       15. The system as set forth in claim 14 and further, said expanding portion of said generally cylindrical tubular member including a lip member extending angularly and radially away from each of said plurality of flexible expansion leaves for biasing said first and second construction elements together as said dowel member is introduced into said expanding portion. 
     
     
       16. The system as set forth in claim 10 and further, said connecting bores of said first and second construction elements comprising a first end portion, a second end portion, and a middle portion, said first end portion extending between said middle portion and said first end of said connecting bore, said second end portion extending between said middle portion and said second end of said connecting bore, said first and second end portions having generally the same radius, said middle portion having a smaller diameter than the diameter of said first and second end portions. 
     
     
       17. The system as set forth in claim 16 and further, said locking means comprising a generally elongate expansion member having a first end and a second end, said first end having a lip member for engagement with said first end portion of said connecting bore of said first construction element, said second end having a lip member for engagement with said second end portion of said connecting bore of said second construction element, and said second end of said elongate expansion member being capable of radially expanding so as to bias said first construction element towards said second construction element. 
     
     
       18. The system as set forth in claim 16 and further, said second generally planar surface of said first and second positioning means including a rim portion extending generally perpendicularly from the plane of said connecting bore of said first and second positioning means, said rim portion being dimensioned to engage with said first end portion of said connecting bore of said first and second construction element. 
     
     
       19. A method of rigidly joining a first construction element to a second construction element, comprising the steps of: (a) providing a first and a second construction element, said first and second construction elements each having a connecting bore extending between a first surface and a second surface, and at least one engagement groove formed in one of said first and second surfaces;   (b) providing first positioning means having a connecting bore extending between a first surface and a second surface, a first pair of engagement ribs extending laterally away from a first end of said connecting bore along said first surface, and a second pair of engagement ribs extending laterally away from a second end of said connecting bore along said second surface;   (c) providing partially expandable locking means for locking said first and second construction elements in fixed relation about said positioning means;   (d) arranging said positioning means between said first and second construction elements such that said connecting bore of said positioning means is substantially coaxial with said connecting bore of said first construction element and said connecting bore of said second construction element, said first pair of engagement ribs is cooperatively coupled with said at least one engagement groove in said first construction element;   (e) arranging said locking means so as to extend at least partially within said connecting bores of said first and second construction elements and at least partially within said connecting bore of said positioning means; and   (f) partially expanding said partially expandable locking means to affix said first construction element in fixed and rigid relation to said second construction element.   
     
     
       20. The method as set forth in claim 19 and further, said step (b) comprising the further sub-step of providing second positioning means having a connecting bore extending between a first surface and a second surface, a first pair of engagement ribs extending laterally away from a first end of said connecting bore along said first surface, and a second pair of engagement ribs extending laterally away from a second end of said connecting bore along said second surface. 
     
     
       21. The method as set forth in claim 20 and further, said step (d) comprising the further sub-steps of: (i) matingly engaging said second pair of engagement ribs of said second positioning means within said at least one engagement groove of said second construction element; and (ii) selectively engaging said second pair of engagement ribs of said first positioning means with said first pair of engagement ribs of said second positioning means to thereby selectively orient said first construction element relative to said second construction element.